Swing automation for rope shovel

• US 10,227,754 B2
• Filed: 01/09/2017
• Issued: 03/12/2019
• Est. Priority Date: 04/14/2011
• Status: Active Grant

• Current Assignee: Joy Global Surface Mining Inc. (Mitsui & Company Limited)
• Original Assignee: Joy Global Surface Mining Inc. (Mitsui & Company Limited)
• Inventors: Taylor, Wesley P., Linstroth, Michael J.
• Primary Examiner(s): Shudy, Angelina
• Application Number:
  US15/401,620
• Publication Number:
  US 20170114527A1
• Time in Patent Office: 792 Days
• Field of Search: 701 50, 414694
• CPC Class Codes: E02F 3/308 working outwardly
• CPC Class Codes: E02F 3/435 for dipper-arms, backhoes or the like
• CPC Class Codes: E02F 3/437 providing automatic sequences of movements, e.g. linear excavation, keeping dipper angle constant
• CPC Class Codes: E02F 3/439 Automatic repositioning of the implement, e.g. automatic dumping, auto-return E02F3/438 takes precedence
• CPC Class Codes: E02F 3/46 with reciprocating digging or scraping elements moved by cables or hoisting ropes ; Drives or control devices therefor E02F3/205, E02F3/905 take precedence
• CPC Class Codes: E02F 3/54 Cable scrapers E02F3/48, E02F3/52 take precedence
• CPC Class Codes: E02F 7/026 mounted on machines equipped with dipper- or bucket-arms
• CPC Class Codes: E02F 7/04 Loading devices mounted on a dredger or an excavator loading devices in general B65G hopper dredgers, also equipment for unloading the hopper
• CPC Class Codes: E02F 7/06 Delivery chutes or screening plants or mixing plants mounted on dredgers or excavators for back-filling E02F5/226 takes precedence; separating equipment in general B03; delivery chutes in general B65G
• CPC Class Codes: E02F 9/2033 Limiting the movement of frames or implements, e.g. to avoid collision between implements and the cabin sub-groups of E02F3/431 of E02F3/435 take precedence; for turntables E02F9/123
• CPC Class Codes: E02F 9/2045 Guiding machines along a predetermined path for graders E02F3/841; machines for construction of roads E01C19/004
• CPC Class Codes: E02F 9/264 Sensors and their calibration for indicating the position of the work tool

Abstract

A system and method for various levels of automation of a swing-to-hopper motion for a rope shovel. An operator controls a rope shovel during a dig operation to load a dipper with materials. A controller receives position data, either via operator input or sensor data, for the dipper and a hopper where the materials are to be dumped. The controller then calculates an ideal path for the dipper to travel to be positioned above the hopper to dump the contents of the dipper. In some embodiments, the controller outputs operator feedback to assist the operator in traveling along the ideal path to the hopper. In some embodiments, the controller restricts the dipper motion such that the operator is not able to deviate beyond certain limits of the ideal path. In some embodiments, the controller automatically controls the movement of the dipper to reach the hopper.

Claims

1. A mining shovel comprising:

a hoist motor;

a crowd motor;

a swing motor;

motor position sensors including a hoist motor position sensor, a crowd motor position sensor, and a swing motor position sensor;

a dipper that is operable to dig and dump materials and that is positioned via operation of the hoist motor, the crowd motor, and the swing motor;

a display; and

a processor coupled to the display and the motor position sensors, and configured to

determine, based on signals from the motor position sensors during operation of the mining shovel, a current hoist position of the dipper, a current crowd position of the dipper, and a current swing position of the dipper,

determine an ideal hoist position of the dipper, an ideal crowd position of the dipper, and an ideal swing position of the dipper, and

provide operator feedback, on the display, the operator feedback indicating the current hoist position, the current crowd position, and the current swing position determined based on the signals from the motor position sensors, and indicating the ideal hoist position, the ideal crowd position, and the ideal swing position,

wherein the operator feedback on the display further indicates previous hoist positions of the dipper, previous crowd positions of the dipper, and previous swing positions of the dipper along with indicating the current hoist position, the current crowd position, the current swing position, the ideal hoist position, the ideal crowd position, and the ideal swing position, and

wherein the previous hoist positions, the previous crowd positions, and the previous swing positions are displayed on a time scale.

2. The mining shovel of claim 1, wherein, to provide the operator feedback, the display indicates the current hoist position and the ideal hoist position in a first hoist window, the current crowd position and the ideal crowd position in a second crowd window, and the current swing position and the ideal swing position in a third swing window.

3. The mining shovel of claim 1, the display further including a crowd-hoist window, the crowd-hoist window depicting the ideal position of the hoist, the ideal position of the crowd, and a crowd-hoist point indicative of the current position of the hoist and of the current position of the crowd.

4. The display of claim 3, wherein the crowd-hoist window includes a four-quadrant x-y axis plot, wherein the ideal position of the hoist is illustrated as a first axis, the ideal position of the crowd is illustrated as a second axis, and the crowd-hoist point is plotted on the four-quadrant x-y axis plot.

5. The mining shovel of claim 3, the display further including a position arc, the position arc including an area signifying the ideal swing position and a swing point representing the current swing position.

6. The mining shovel of claim 1, wherein the display includes an indication that indicates an assessment of a relation between at least one selected from the group consisting of

the current hoist position and the ideal hoist position,

the current crowd position and the ideal crowd position, and

the current swing position and the ideal swing position.

7. The mining shovel of claim 1, wherein the display is at least one selected from the group comprising a light emitting diode position panel, a heads up display, and a display screen on a device.

8. The mining shovel of claim 1, wherein the display includes at least one gauge, the at least one gauge including at least one selected from the group consisting of the current position of the hoist and the ideal position of the hoist, the current position of the crowd and the ideal position of the crowd, and the current position of the swing and the ideal position of the swing.

9. A method of generating an operator feedback display for a dipper of a shovel, the method comprising:

controlling movement of the dipper via operation of a hoist motor, a crowd motor, and a swing motor;

determining, by a processor, an ideal hoist position of the dipper, an ideal crowd position of the dipper, and an ideal swing position of the dipper;

determining, by the processor, a current hoist position of the dipper, a current crowd position of the dipper, and a current swing position of the dipper based on signals from motor position sensors during operation of the mining shovel, wherein the motor position sensors include a hoist motor position sensor, a crowd motor position sensor, and a swing motor position sensor; and

providing operator feedback, by the processor on the display, that indicates the current hoist position, the current crowd position, the current swing position determined based on the signals from the motor position sensors, and indicates the ideal hoist position, the ideal crowd position, and the ideal swing position,

wherein the operator feedback on the display further indicates previous hoist positions of the dipper, previous crowd positions of the dipper, and previous swing positions of the dipper along with indicating the current hoist position, the current crowd position, the current swing position, the ideal hoist position, the ideal crowd position, and the ideal swing position, and

wherein the previous hoist positions, the previous crowd positions, and the previous swing positions are displayed on a time scale.

10. The method of claim 9, wherein the operator feedback indicates the current hoist position and the ideal hoist position in a first hoist window, the current crowd position and the ideal crowd position in a second crowd window, and the current swing position and the ideal swing position in a third swing window.

11. The method of claim 9, wherein providing the operator feedback includes displaying a crowd-hoist window, the crowd-hoist window depicting the ideal hoist position, the ideal crowd position, and a crowd-hoist point indicative of the current hoist position and of the current crowd position.

12. The method of claim 11, wherein the crowd-hoist window includes a four-quadrant x-y axis plot, wherein the ideal hoist position is illustrated as a first axis, the ideal crowd position is illustrated as a second axis, and the crowd-hoist point is plotted on the four-quadrant x-y axis plot.

13. The method of claim 11, wherein providing the operator feedback includes displaying a position arc, the position arc including an area signifying the ideal swing position and a swing point representing the current swing position.

14. The method of claim 9, further including generating, on the display, an indication that indicates an assessment of a relation between at least one selected from the group consisting of the current hoist position and the ideal hoist position,

the current crowd position and the ideal crowd position, and

the current swing position and the ideal swing position.

15. The method of claim 9, wherein the display is at least one selected from the group comprising a light emitting diode position panel, a heads up display, and a display screen on a device.

16. The method of claim 9, wherein providing the operator feedback includes generating at least one gauge, the at least one gauge including at least one selected from the group consisting of the current hoist position and the ideal hoist position, the current crowd position and the ideal crowd position, and the current swing position and the ideal swing position.